Ferroli GNI User manual

Supplied By www.heating spares.co Tel. [phone]
GN1
CAST IRON HIGH EFFICIENCY SECTIONAL BOILER,
FOR GAS/OIL FUELS

Supplied By www.heating spares.co Tel. [phone]
2

Supplied By www.heating spares.co Tel. [phone]
3
Index
1. Technical informations
2. Dimensions and technical data
3. Packing and shipping details
4. Installation
5. Testing
6. Service
7. Boiler components
8. Option

Supplied By www.heating spares.co Tel. [phone]
4
Fig. 1
1. Technical informations
1.01 Introduction
GN1 boiler is a new heating generator with high efficiency, for central heating system as well sanitary hot
water production suitable for burners using oil or gas.
Theboilerbodyisbuiltbycastironsectionsjoinedtogheterbymeanofbiconicalnipplesandtierods.Sections
finsareespeciallydevelopedtoachievethebestefficiencyoftheboilerinordertosaveonfuelconsumption.
The boiler body insulation is provided by mineral high density fibers that minimizes the body heat lost.
Key
1 Timer sochet
2 Thermomanometer
3Security thermostat manual resetting
4Main switch
5 Control thermostat
1.02 Control and securities devices operation
Regulating thermostat, manual resetting 3 (fig. 1)
It operates when the boiler temperature, during the heating mode reach such a level that can use a danger
situation. Before resetting this thermostat ask for Qualified Serviceman to inspect the appliance.
Central thermostat 5 (fig. 1)
It allows to control the boiler temperature by mean of its knobs.
This thermostat controls the burner.
Room thermostat (not supplied)
This device is not supplied, but can be fitted by installer, it is connected in series to the control thermostat
anditmanagesboththeburnerandthecirculatingpumpduringtheheatingmode.Theuseofsuchappliance
is advised to get a better comfort as well on energy saving.

Supplied By www.heating spares.co Tel. [phone]
5
Fig. 2
2. Dimensions and technical data
2.01 Dimensions and technical data (fig. 2 - tab. 1)
Key
a1 Flow 11/2"
a2 Return 11/2"
a3 Boiler drain 11/2"
N.B.: - Max. water temperature for the heating system is 90°C. - Min. water temperature for the heating
system is 45°C.
a1
64
1/2''
85
1 1/2''
a3
400
23
850
14 5
542
1 1/2''
Ø
A
80
274
a2
711
B
Water
load losses
Model
Heat and
D.H.W.
(gross)
gas
Max.
28,6
43
57,3
71,6
86,1
100,4
114,7
Heat and
D.H.W.
output
Max.
23,3
34,9
46,5
58,1
69,8
81,4
93,0
Heat and
D.H.W.
(net)
gas+oil
Max.
25,8
38,7
51,6
64,5
77,5
90,4
103,3
Heat and
D.H.W.
(gross)
gas
Min.
18,2
18,2
39,3
49,1
59,1
68,8
78,6
Heat and
D.H.W.
(net)
gas+oil
Min.
16,4
16,4
35,4
44,2
53,2
62,0
70,8
Heat and
D.H.W.
output
Min.
15,0
15,0
32,5
40,5
48,8
57,0
65,0
N°
element
2
3
4
5
6
7
8
Water
capacity
dm
3
11
14
17
20
23
26
29
Combustion
chamber
lenght
mm
286
386
486
586
686
786
886
Combustion
chamber
dimension
Ømm
260x310
260x310
260x310
260x310
260x310
260x310
260x310
Model
GN1 02
GN1 03
GN1 04
GN1 05
GN1 06
GN1 07
GN1 08
GN1 02
GN1 03
GN1 04
GN1 05
GN1 06
GN1 07
GN1 08
Working
pressure
bar
4
4
4
4
4
4
4
A
300
400
500
600
700
800
900
B
105
105
105
105
125
125
125
Ø
130
130
130
180
180
180
180
Combustion
chamber
load loss
∆p mbar
0,2
0,2
0,2
0,2
0,2
0,2
0,2
Combustion
chamber
volume
dm
3
12,09
20,15
28,21
36,27
52,39
60,45
68,51
∆t 10
1
1,8
4,2
7,2
11
15
20
∆t20
-
-
1
1,6
2,3
3,3
4,5
Weight
of unit
kg.
75
100
125
150
175
200
225

Supplied By www.heating spares.co Tel. [phone]
6
2.02 Pressure drop (fig. 3)
Pressure drops according to the boiler size are specified on the following diagram and refer to temperature
difference between flow and return comprises between 10 and 20°C.
Fig. 3
3. Packing and shipment
Boiler is delivered complete assembled in a wood crate.
Fig. 4

Supplied By www.heating spares.co Tel. [phone]
7
Electrical diagram
LN
CA
11
CA
B
C
TR
TS
IL
TR
BC
230V
50Hz
TS
IL
NL
230V
50Hz
1
12
7
8
N
4
12124657 11109
1
10
8
5
9
2
C
C
2
1
3
2
L
3
6
MAIN SWITCHIL =
CONNECTION AUXILIARYCA =
BOILER THERMOSTATTR =
SAFETY THERMOSTATTS =
BURNERB =
CIRCULATING PUMPC =
AVAILABLE CLAMPS11-12 =
REMOVE THE LINE IF ROOM
THERMOSTAT IS FITTED
4. Installation
It is law that all gas appliances are installed by Competent Persons, in accordance with the regulations.
Failureto installappliances correctlylead toprosecution, itis yourown interest,and thatof safety,to ensure
thatthelawiscopliedwith.ManufacturersinstructionsmustNOTbetakeninanywayasover-ridingstatutory
obligations, special care must be paid to conform with law and regulation concerning building and location
of the chimney.
4.01 Electrical connection
Proceed to wire pump, burner and optional room thermostat. According to the wiring diagrams (fig.5) and to
thedirectionsattachedtothecables.Itisrecommendedtoinstallatwo-poleswitchbetweenthepowersupply
and the boiler. The switch contacts must have a clearance of at least 3 mm and fuses of 5 A max must be
provided.
N.B. - Appliance must be earthed.
It is recommended to connect the boiler to a good electric earth system.
FERROLI could not be considered responsable for any kind of damage to Persons or things caused
by failure of earthing the system.
Fig. 5

Supplied By www.heating spares.co Tel. [phone]
8
4.02 Hydraulic connections
Boiler must be connected to the system according to boiler back part indications and those provided at fig.
2.Pipemustbefree ofanykindofstrainand securityvalvesmustbeprovidedin both centralheatingsystem
and domestic hot water system location of such security valves be as close is possible to the boiler and
between the boiler and valve no obstructions or gate valves must be placed.
Theboiler is not supplied withexpansion tankit hasto be providedduring theboiler installation.It is advised
thatthe pressure in the hydraulicsystem hasto bebetween 0,5 and1 barmeasured incold water condition.
4.03 Connection to the chimney
It is recommended to connect the boiler to a good working chimney built according to the regulations. The
connection between boiler and chimney must be done by using suitable material proof against high
temperature and corrosion. Where flue sections have to be connected it is advised pay attention to avoid
leaking and provided good insulation through all the flue length to avoid condensing problem.
5. Testing
5.01 Before the first light of the boiler
Before the first light of the boiler follow these check list:
a)check the system is filled with water at the right pressure;
b)check against any leakage of water fuel;
c)check that the correct electric power is supplied to the unit;
d)check size and perfect flue installation;
e)check against any type of flammable materials where the boiler is installed;
f) check the burner has the right heat input according to the boiler size;
g)control that the water valves are open.
5.02 First lighting
After the boiler preliminaries checking , the appliance can be lights in the following way;
1) Open the fuel gate valve.
2) Set the regulating thermostat at the required temperature level.
3) Give electric power to the boiler and switch on the main switch 4 (fig. 1) on the boiler control panel.
After above operations the burner will start to run and the boiler will begin to work.
5.03 After the first lighting
After the first lighting it is advisable check:
burner works properly, this checking must be done by appropriate instruments.
Thermostats operate correctly.
Water flows through the system.
Smoke gases evacuate through the flue duct.

Supplied By www.heating spares.co Tel. [phone]
9
5.04 Switch off
To turn off the unit for a short period it is enough to switch off the switch 4 (fig. 1) on the control panel.
If the boiler has to be stopped for long period beside to act by the switch 4, it is necessary to cut the supply
of fuel by mean of the gate valve, in winter season, to avoid damages due to the frost it is necessary to add
the antifrost liquid in the system or to drain it completely.
6. Service
The after sale service must be carried out only Qualified Plumbers. It is advise to service the boiler at least
once a year, before the winter season. Check must include the boiler cleaning, the perfect operation of the
controls and the burner.
Furthermore the flue duct conditions have to be inspected.
6.01 Boiler cleaning
Cut out electric power.
The front panels 1, 2, 3 (fig. 6).
Clean the boiler internal parts.
Check the flue duct and if necessary clean it.
The burner service must be done according the Manufacture Instructions.
3
Tube Brush
Tube Brush
2
1
Fig. 6

Supplied By www.heating spares.co Tel. [phone]
10
7. Boiler parts
POS. CODE DESCRIPTION
133004920 FRONT SECTION
233004710 REAR SECTION
333004720 MIDDLE SECTION
434204000 BICONICAL NIPPLE
534400010 THE ROD M10x140
534403010 THE ROD M10x245
534400910 THE ROD M10x340
534400920 THE ROD M10x440
534400930 THE ROD M10x540
534403170 THE ROD M10x630
534403180 THE ROD M10x740
633100600 REAR INSULATION D140
633100610 REAR INSULATION D180
733202060 BURNER DOOR
733202080 BURNER DOOR
833202100 SPY HOLE COVER
933202120 UPPER DOOR
10 33400720 PROBES POCKET
11 34000610 PLUG
12 34000640 FASTENING PIN
13 34010220 STUD
14 36401780 PLASTIC PLUG
15 35000390 TUBE BRUSH
16 35003370 MULTIFUNCTIONAL CONTROL
SISTEM (not supplied)
17 35002420 KNOB
18 35316550 ISOLATION PANEL
19 35316340 ISOLATION PANEL
20 36400790 THERMOHYDROMETER
21 36401450 SECURITY THERMOSTAT
22 36401210 BOILER THERMOSTAT
26 36901140 NO RETURN VALVE
27 37025600 FRONT PANEL
28 37025610 RIGHT PANEL FOR GN1 02
28 37025620 RIGHT PANEL FOR GN1 03
28 37025630 RIGHT PANEL FOR GN1 04
28 37025640 RIGHT PANEL FOR GN1 05
28 37025650 RIGHT PANEL FOR GN1 06
28 37025660 RIGHT PANEL FOR GN1 07
28 37025670 RIGHT PANEL FOR GN1 08
29 37025680 LEFT PANEL FOR GN1 02
29 37025690 LEFT PANEL FOR GN1 03
29 37025700 LEFT PANEL FOR GN1 04
29 37025710 LEFT PANEL FOR GN1 05
29 37025720 LEFT PANEL FOR GN1 06
29 37025730 LEFT PANEL FOR GN1 07
29 37025740 LEFT PANEL FOR GN1 08
30 37025750 COVER FOR GN1 02
30 37025760 COVER FOR GN1 03
30 37025770 COVER FOR GN1 04
30 37025780 COVER FOR GN1 05
30 37025790 COVER FOR GN1 06
30 37025800 COVER FOR GN1 07
30 37025810 COVER FOR GN1 08
31 38508420 COMPLET CONTROL PANEL
32 31000210 SPRING
33 31000260 PLATE SPRING
34 31132520 REAR PANEL FOR GN1 02-03
34 31132540 REAR PANEL FOR GN1 04-08
35 31205870 CLAMP
37 35005150 BARE CONTROL PANEL
38 36100290 SWITCH
39 32910840 WIRING BOX
40 32910760 WIRING BOX COVER
41 35002880 PLASTIC PLUG
40
39